Scouring composition board



Nov. 12, 1968 s. A. HIDER ET AL 3,409,927

SCOURING COMPOSITION BOARD Filed Oct. 23, 1965 United States Patent3,409,927 SCOURING COMPGSITIQN BOARD Shibley A. Hider, Toledo, and Klahrl). Loudenslagel, Maumee, Ohio, assignors to Owens-Illinois, Inc., acorporation of Ohio Filed Oct. 23, 1965, Ser. No. 503,612 Claims. (Cl.15209) This invention is concerned with scouring composition boards.More specifically, this invention is concerned with a scouringcomposition board that is formed from one layer of a pulp-thermoplasticboard and one fibrous layer.

Scouring devices wherein a fibrous pad is bound to sheets, for exampleplastics, foams, paper, etc., are known in the prior art. These priorart pulp-thermoplastic boards are usually produced by securing a fibroussheet to a backing sheet via an adhesive. The scouring compositionboards of this invention are distinguished from the prior art structuresin that a fibrous pad is bound to a pulp-thermoplastic board with theresult that a superior product is produced. Likewise, the scouringcomposition boards of this invention are advantageous because they canbe cheaply manufactured on a continuous basis.

The primary object of this invention is the production of a superiorscouring composition board. More specifically, an object of theinvention at hand is a superior scouring composition board that containsa pulp-thermoplastic board and a fibrous pad.

A plurality of pulp-plastic boards which are formed from a wood pulp anda plastic are known in the prior art. This invention is adapted toutilize these prior art structures. However, this invention isparticularly adapted to utilize a superior pulp-thermoplastic board thatis p oduced from a filbrillated pulp. These superior pulpthermoplasticboards will-be described in detail herein below.

The scouring composition board of the subject invention is generallyillustrated in FIGURES 1 through 3.

FIGURE 1 shows an embodiment 2 of this invention wherein a fibrousmember 4 is bonded to a single pulpthermoplastic board.

FIGURE 2 represents anotherembodiment 8 of this invention wherein afibrous member 4 is bonded to two pulp-thermoplastic boards 6 and 10.

FIGURE 3 illustrates how embodiment 8 of FIGURE 2 may be utilized.

To be more specific, the scouring composition board structure as isillustrated in FIGURE 1 comprises a pulpthermoplastic board to which isbonded a fibrous member 4 which may be, for example, a metal wool.

In the embodiment of the invention at hand, as is illustrated in FIGURE2, a composite scouring composition board comprises twopulp-thermoplastic boards 6 and which are bonded to a central fibrousmember 4.

FIGURE 3 illustrates how composite structure 8 can be divided to formtwo scouring composition boards just prior to use by the consumer.

Pulp-thermoplastic board layers 6 and 10 are formed from a mixture of atleast one cellulosic material and at least one thermoplastic material.

Examples of cellulosic materials which are adopted to this phase of thesubject invention include wood cellulose and pulps derived fromhardwoods, softwoods, and woody annular plants such as balsam fir,eastern hem- Patented Nov. 12, 1968 lock, jack pine, eastern white pine,red pine, black spruce, red spruce, white spruce, tamarack, cyprus,quaking aspen, American beech, paper birch, yellow birch, easterncottonwood, sugar maple, silver maple, yellow poplar, black cherry,white oak, bagasse, hemp, cotton and jute; mixtures of cellulosicmaterials can also be used. Preferred pulps adapted for the preparationof pulp-thermoplastic boards 6 and 10 are softwood pulps produced fromwoods such as pine, spruce, etc. No special prior refining is necessaryfor the pulps to be used in the practice of the present invention. Thepulp-particulate thermoplastic mixture can contain from about 20 toabout 90 weight percent pulp. A more preferred range for pulpconcentration is from about 40 to about 60 weight percent with a mostpreferred percentage being weight mrcent. Mixtures of cellulosicmaterial can also be utilized.

The above-described pulps are blended with from about 20 to about 90weight percent of a thermoplastic material. A more preferredfiber-thermoplastic mixture contains from about 40 to about Weightpercent of a particulate thermoplastic material with a most preferredcomposition containing 50 weight percent of a particulate thermoplasticmaterial. Examples of thermoplastics which are suited for use in thisphase of the subject invention include both homopolymeric andcopolymeric resins, such as (1) vinyl resins formed by thepolymerization of vinyl halides or by the copolymerization of vinylhalides with unsaturated polymerizable compounds, e.g., vinyl esters,a,B-unsaturated esters, a,B-unsaturated ketones, a,B-unsaturatedaldehydes and unsaturated hydrocarbons such as butadienes and styrenes;(2) poly-u-olefins, such as polyethylene, polypropylene, polybutylene,polyisoprene and the like, including copolymers of poly-a-olefins; (3)polyurethanes such as are prepared from polyols and organicpolyisocyanates; (4) polyamides such as polyhexamethylene adipamide; (5)polyesters such as polymethylene terephthalates; (6) polycarbonates; (7)polyacetals; (8) polyethylene oxide; (9) polystyrene, includingcopolymers and terpolymers of styrene with monomeric ompounds such asacrylonitrile and butadiene; (10) acrylic resins as exemplified by thepolymers of methyl acrylate, acrylamide, methylol acrylamide,acrylonitrile, and copolymers of these with styrene, vinyl pyridines,etc.; (11) neoprene; (l2) condensates of aldehydes, especiallyformaldehyde and formaldehyde engendering substances such asparaformaldehyde; (l3) silicones such as dimethyl and methyl hydrogenpolysiloxanes; (14) unsaturated polyesters; and (15) cellulose estersincluding the nitrate, acetate, propionate, etc. This list is not meantto be limiting or exhaustive but merely to illustrate the wide range ofpolymeric materials which may be employed in the present invention.

Preferred thermoplastic polymers adapted for use in this invention aregenerally of low polarity and density. Examples of these preferredpolymers are hydrophobic polymers such as those derived from olefinichydrocarbons having fromone to twelve carbon atoms, homopolymers andcopolymers of ethylene, propylene, l-butene, nylon, styrene, vinylchloride, polybutadiene, and polyisoprene. However, the thermoplasticcan be low density or high density, low molecular weight or highmolecular weight, and low melting or high melting. Mixtures of polymerscan also be used.

Fibrous member 4 can be any fibrous material which is suitable forscouring. Fibrous member 4 can have both a random and an orderlystructure. For example, it can be an orderly structure such as a wovenmetal mat or a random structure such as a metal wool. More specifically,member 4 can be a woven mat or a wool of a metal such as steel,stainless steel, brass, copper, aluminum, etc. Inorganic substances suchas glass can also be utilized in the formation of fibrous member 4. Thatis, member 4 can be a woven glass fiber mat or glass wool.

It is to be noted that fibrous member 4 can also be corrugated in orderto increase its scouring efficiency. Likewise, it is obvious to oneskilled in the art that many other types of designs can be pressed intomember 4 in order to increase its scouring efficiency.

In order to increase the cleaning efficiency of the subject scouringcomposition boards, fibrous member 4 can be coated with or impregnatedwith a soap. In this connection, the term soap is intended to embracenot only the salts of one or more of the higher fatty acids with analkali metal but also the newer detergents, some of which are not saltsof fatty acids, e.g., those based on sodium dodecyl benzene sulfate,sulfonsate fatty acid amides and the like. Fibrous member 4 can likewisebe coated with an antioxidant which will prevent its oxidation when usedin an oxidizing environment.

Preferred scouring composition boards 2 and 8 in accordance with theembodiments with this invention as are illustrated in FIGURES 1 and 2,are prepared by the combination of at least one pulp-thermoplastic board6 and/ or that is formed from about 40 to about 60 percent kraft pulpand from about 60 to about 40 percent polyethylene, polystyrene orpolyvinyl chloride.

The most preferred embodiments 2 or 8 of this invention as areillustrated by FIGURES l and 2, comprises a pulp-thermoplastic board 6and/or 10 which comprises from about 40 to about 60 percent kraft pulpand from about 60 to about 40 percent polyethylene. To thispulpthermoplastic board is bonded a fibrous member 4 which is steelwool.

The above-described pulps and thermoplastics can be combined to formpulp-thermoplastic board layers 6 and 10 by many methods. For example, apowdered thermoplastic can be blended with a dry pulp and subsequentlyfused by the application of heat and pressure. Likewise, a dry pulp canbe kneaded into a thermoplastic material which is in a semi-plasticstate. The thermoplastic material can also be blended into a slurrywhich comprises a pulp and a slurry media, dried and then fused.

As mentioned above, a superior pulp-thermoplastic board can be preparedby the beating of a slurry which comprises a particulate thermoplasticmaterial, pulp and a slurry medium. This beating effects thefibrillation of the pulp and the entrapment of the particulatethermoplastic material. When using this fibrillation technique toproduce a pulp-thermoplastic board, the thermoplastic is in aparticulate form and should range in size between 40 and 300 mesh.Within the useful range of 40 to 300 mesh, there is a preferred range of100 to 200 mesh.

Liquid slurry media which are adapted for use to produce thepulp-thermoplastic board using fibrillation include for example,hydrocarbons such as benzene, toluene, and heptane; mildly polarsubstances, for example, ethers such as ethyl ether and tetrahydrofuran;ketones such as Z-butanone; and highly polar solvents, for example,hydroxy compounds such as Water, methanol, and ethanol. Althoughconvenience determined by routine test will usually establish thepreferred medium in a particular application, the only substantiallimitation on the medium is that it must not decompose or completelydissolve the cellulosic or the thermoplastic component under theconditions selected. Non-aqueous media which meet this requirement aresuitable, but aqueous media have practical advantages because of theirlower cost and customary use in the art for paper-making processes.

The fibrillation necessary to produce the preferred pulp- .4thermoplastic boards for use in this invention is that which provides adecrease of TAPPI freeness value of the pulp alone of at least 25 ml.below the freeness value prior to treatment, and provides a final TAPPIfreeness value of the pulp alone of from about 300 ml. to about 600 ml.A preferred range for the final value of the pulp is a TAPPI freeness offrom about 375 ml. to about 425 ml. It is to be noted that the freenessof the resulting mixture can also be measured. However, these values areusually slightly higher due to the effect of the particulatethermoplastic. When measuring the freeness of the composite mixture, thepreferred final freeness falls within the range of from about 425 ml. toabout 475 ml.

It will be apparent from the foregoing that not all types of agitationare applicable to provide the fibrillation necessary to obtain theproducts of the present invention. The degree of fibrillation suitablefor the practice of this invention, however, can be defined in terms ofthe TAPPI freeness or Williams Slowness. Specifications for the TAPPItest T 227 m58, Freeness of Pulp, as revised August 1958, are availablefrom the Technical Association of the Pulp and Paper Industry, 360Lexington Avenue, New York 17, N.Y. The test is based on a measurementof rate of water drainage from a standardized pulp suspension through aperforated plate. The filtrate enters a funnel which is equipped withside and bottom orifices; the quantity of water which is collected fromthe side orifice is a measure of drainage rate, and this quantity inmilliliters is TAPPI freeness. Tests for the present invention were madeon a Williams Precision Freeness Tester (Williams Apparatus 00.,Watertown, N.Y.), which allows measure of drainage time rather thanvolume. Values from the two freeness tests are interconvertible byscales available from TAPPI at the address given above.

The fibrillation as described above is carried out on a slurry that isformed between a fiber-particulate thermoplastic mixture aud a liquidmedium as described above. As is mentioned, aqueous media are preferredfor use in this invention.

The slurry concentration can range from about 0.01 to about 2 percent. Apreferred range is from about 0.5 to about 1 percent. Generally, theslurry should be of such a consistency that it is possible to form apaper-like sheet on a conventional paper making machine such as afourdrinier.

Upon formation of the fibrillated fiber-particulate thermoplasticmixture as described above, said mixture is fed directly into aconventional paper making machine such as a fourdrinier machine. Thecoating of particulate thermoplastic on the fibrillated fibers is suchthat it is still possible to form fiber-to-fiber contact. Because ofthis fiber-to-fiber contact, a wet sheet of suitable strength to allowthe use of a conventional paper making machine can be formed. The Wetsheet upon formation can be dried with the dryers that are used to dryconventional paper. It is recognized by one skilled in the art, thetemperature of the dryers and feed speed must be adjusted to cause thedrying of the wet sheet. Upon drying, the sheet is formed into afinished product by the addition of heat and or pressure.

The above-described preferred pulp-thermoplastic boards which areproduced by fibrillation are described in detail in U.S. Patent No.3,325,345.

Upon formation, the above-described pulp-thermoplastic boards are formedinto the scouring composition boards of this invention by theapplication of at least one of heat and pressure. In the production ofscouring composition boards 2 and 8 as are illustrated in FIG- URES 1and 3, the individual pulp-thermoplastic boards 6 and 10 may be combinedwith fibrous member 4 in an unfused state. Likewise, thepulp-thermoplastic boards 6 and 10 may be fused by the exposure to atemperature of from about 250 to about 400 F. at a pressure of fromabout to about 1000 p.s.i.g. prior to their combination with the fibrousmember 4. During bonding with the pulp-thermoplastic board, fibrousmember 4 may be protected with a non-adherent sheet such as Teflon. Thisprotection allows the fibrous sheet to retain its fluify nature afterbonding.

In regard to the above-described fabricating techniques, it should benoted that it is preferred that the pulp-thermoplastic boards be in anunfused state when combined with fibrous member 4. This procedureproduces a superior bond between the pulp-thermoplastic board and thefibrous member.

It is within the purview of this invention to add to the compositions ofthis invention compatible materials which do not affect the basic andnovel characteristics of the composition of this invention. Among suchmaterials are coloring agents, including dyes and pigments, fillers andsimilar additives. Additives such asantioxidants, antistatic agents,stabilizers and anti-foaming agents may also be added. The upper limitof the quantity of additives is usually about 25 weights percent of theproduct.

It is to be noted that upon production of the finished fused material ofthis invention, said material is in sheet form. This sheet can then becorrugated, heat sealed, sealed with adhesives, formed into a roll,perforated, printed, embossed, etc.

The composition boards of this invention can be manufactured on acontinuous or batch basis. If the preferred fibrillationpulp-thermoplastic board is utilized and said sheet is manufactured on afourdrinier paper making machine, the board from the fourdrinier machinecan be easily combined with the other components of the productcomposition board on a continuous basis.

The following examples will illustrate the invention. These examples aregiven for the purpose of illustration and not for the purpose oflimiting this invention.

Example I Two unfused sheets of 30% kraft pulp and 70% low densitypolyethylene were sandwiched with a layer of grade 0 steel wool. Acut-out metal plate was used as a spacer to prevent compacting of thesteel wool layer. The assembly was pressed using a Carver press betweenheated platens at a pressure of 300 p.s.i.g., for 75 seconds at 375 F.The resulting sandwich was removed, then lightly pressed without themetal spacer at 360 F. for 60 seconds.

The resulting sandwiched laminate was then pulled apart, producing twofused pulp-plastic boards with steel wool facings. The individualscouring composition boards functioned as a wet-or-dry abrasive and werenon clogging.

Example 11 A square mat of grade 0 steel wool was placed on an unfusedpulp-thermoplastic board which was formed from 30% kraft pulp and 70%low density polyethylene. A sheet of Teflon was then placed over thesteel wool. A picture frame spacer of approximately thick with a squarehole in its slightly smaller than the piece of steel wool was placedaround the steel wool mat. This assembly was pressed using a Carverpress between platens at 450 p.s.i.g. for 90 seconds at 385 F. Thismethod produced a pulp-thermoplastic board having a thick fiutfy steelwool mat. Since the hole in the frame is slightly smaller than the sizeof steel Wool mat, the edges of the mat were tightly sealed topulp-thermoplastic board. The other surfaces of the steel wool mat weresecured to the pulp-thermoplastic board to a lesser degree.

The resulting scouring composition board functioned as a wet or dryscouring agent.

Example III Two unfused pulp-thermoplastic boards consisting of 50% highdensity polyethylene (density .960 and melt index 14) and 50% pine kraftpulp were sandwiched around a non-woven mat 0A thick) of glass wool. The

composite was fused using a Carver press between heated platens at 375F., and 600 p.s.i.g. for 1 minute. The fused pulp-plastic boards werethen separated with a glass wool layer adhering to each. The resultingtwo abrasive boards exhibited mild abrasive action when rubbed against apainted surface under both dry and wet conditions.

What is claimed is:

1. A scouring composition board which comprises a pulp-thermoplasticboard and a fibrous layer wherein the pulp-thermoplastic board, having adiscrete fibrous web, is produced by the agitation of a slurry for aperiod of time sufiicient to cause fibrillation, said fibrillation beingsufiicient to decrease the TAPPI freeness of said pulp according toTAPPI test T 227 111-58 by at least about 25 ml. to a final value offrom about 300 ml. to about 600 ml., wherein the slurry comprises fromabout 0.01 to about 2 weight percent of a composition havingintermingled therein from about 20 to about weight percent of aparticulate thermoplastic, which will pass through a 40-mesh screen andbe retained by a 300-rnesh screen and from about 80 to about 10 weightpercent of a fibrous cellulose material, the balance of the slurry beingslurry medium, and draining the resulting mixture; wherein the fibrouslayer is steel wool, brass wool, copper wool, aluminum wool or glasswool and is bonded to the pulp-thermoplastic board.

2. The scouring composition board of claim 1 wherein thepulp-thermoplastic board, having a discrete fibrous web, is produced bythe agitation of a water slurry for a period of time suflicient to causefibrillation, said fibrillation being suflicient to decrease the TAPPIfreeness of said pulp according to TAPPI test T 227 m-58 by at least 25ml to a final value of from about 375 ml. to about 425 ml., wherein theslurry comprises from about 0.5 to about 2 percent of a compositionhaving intermingled therein from about 40 to about 60 weight percent ofa particulate thermoplastic polymeric alphaolefin having from one totwelve carbon atoms, which will pass through a 40-mesh screen and beretained by a mesh screen and from about 60 to about 40 weight percentof a wood pulp, the balance of the slurry being slurry medium anddraining the resulting mixture; wherein the fibrous layer is steel wool,and is bonded to the pulp-thermoplastic board.

3. The scouring composition board of claim 1 wherein thepulp-thermoplastic board, having a discrete fibrous web, is :produced bythe agitation of a water slurry for a period of time sufficient to causefibrillation, said fibrillation being sufiicient to decrease the TAPPIfreeeness of said pulp according to TAPPI test T 227 [in-58 by at least25 ml. to a final value of from about 375 ml. to about 425 ml., whereinthe slurry comprises from about 0.5 to about 2 weight percent of acomposition having intermingled therein from about 40 to about 60 weightpercent of a particulate polyethylene, which will pass through a100-mesh screen and be retained by a 200- mesh screen; and from about 60to about 40 weight percent of pine kraft pulp, the balance of the slurrybeing water and draining the resulting mixture; wherein the fibrouslayer is steel wool, and is bonded to the pulpthenmoplastic board.

4. The scouring composition board of claim 1 wherein thepulp-thermoplastic board, having a discrete fibrous Web, is produced bythe agitation of a water slurry for a period of time sufiicient to causefibrillation, said fibrillation being sufiicient to decrease the TAPPIfreeness of said pulp according to TAPPI test T 227 m-58 by at least 25rnl.to a final value of from about 375 ml. to about 425 ml., of a slurrywhich comprises from about 0.5 to about 2 weight percent of acomposition having intermingled therein from about 40 to about 60 weightpercent of a particulate polystyrene, which will pass through a 100-rnesh screen and be retained by 200-mesh screen; and from about 60 toabout 40 weight percent of pine kraft pulp, the balance of the slurrybeing water and draining the resulting mixture; wherein the fibrouslayer is steel wool, and is bonded to the pulp-thermoplastic board.

5. The scouring composition board of claim 1 wherein thepulp-thermoplastic board, having a discrete fibrous web, is produced bythe agitation of a water slurry for a period of time suflicient to causefibrillation, said fibrillation being sufficient to decrease the TAPPIfreeness of said pulp according to TAPPI test T 227 m-58 by at least 25ml., to a final value of from about 375 to about 425 mL, wherein theslurry comprises from about 0.5 to about 2 weight percent of acomposition having intermingled therein from about 40 to about 60 weightpercent of a particulate polyvinyl chloride, which will pass through aIOU-mesh and be retained by a ZOO-mesh screen; and from about 60 toabout 40 weight percent of pine kraft pulp, the balance of the slurrybeing water and draining the resulting mixture; wherein the fibrouslayer is steel wool, and is bonded to the pulp-thermoplastic board.

References Cited UNITED STATES PATENTS 2,845,650 8/1958 Ashley et al.152095 3,298,053 1/1967 Plasse et al. l5--506 FOREIGN PATENTS 948,614 2/1964 Great Britain.

1. A SCOURING COMPOSITION BOARD WHICH COMPRISES A PULP-THERMOPLASTICBOARD AND A FIBROUS LAYER WHEREIN THE PULP-THERMOPLASTIC BOARD, HAVING ADISCRETE FIBROUS WEB, IS PRODUCED BY THE AGITATION OF A SLURRY FOR APERIOD OF TIME SUFFICIENT TO CAUSE FIBRILLATION, SAID FIBRILLATION BEINGSUFFICIENT TO DECREASE THE TAPPI FREENESS OF SAID PULP ACCORDING TOTAPPI TEST T 227 M-58 BY AT LEAST ABOUT 25 ML. TO A FINAL VALUE OF FROMABOUT 300 ML. TO ABOUT 600 ML., WHEREIN THE SLURRY COMPRISES FROM ABOUT0.01 TO ABOUT 2 WEIGHT PERCENT OF A COMPOSITION HAVING INTERMINGLEDTHEREIN FROM ABOUT 20 TO ABOUT 90 WEIGHT PERCENT OF A PARTICULATETHERMOPLASTIC, WHICH WILL PASS THROUGH A 40-MESH SCREEN AND BE RETAINEDBY A 300-MESH SCREEN AND FROM ABOUT 80 TO ABOUT 10 WEIGHT PERCENT OF AFIBROUS CELLULOSE MATERIAL, THE BALANCE OF THE SLURRY BEING SLURRYMEDIUM, AND DRAINING THE RESULTING MIXTURE; WHEREIN THE FIBROUS LAYER ISSTEEL WOOL, BRASS WOOL, COPPER WOOL, ALUMINUM WOOL OR GLASS WOOL AND ISBONDED TO THE PULP-THERMOPLASTIC BOARD.